The conveyors handling products of leading brands such as Mum and Clairol, have saved space, improved efficiency and automated the entire production process. Designed, built and installed by specialist ADM Automation, the system includes nine FlexLink lines handling nearly 68 million units a year. 

“This was an ambitious project involving a lot of people so it was essential to choose the best system”, says Clive Herbert, Engineering Manager at Bristol Myers Co in Tyne & Wear. “We had a number of quotes from other companies but we chose the handling solution offered from ADM Automation because of its flexibility and innovative design.” 

Saving valuable floor space
“Initially we looked at a solution with conveyors at floor level until it became obvious that we would not only lose valuable floor space, but also get limited access to the production cells. We worked closely with ADM Automation utilizing the FlexLink range and came up with a design that actually transports the boxes from the packaging hall to the warehouse by the roof!” 

The conveyors are loaded at low level with a variety of different sized cases. They are elevated on cleated chain at a 45-degree angle up through a hole in the ceiling and into the roof. The conveyors then run along the ceiling to a transfer station. An automatic pusher then moves the case onto another line, which continues, across the ceiling until it reaches the warehouse. The conveyor then drops down through another hole in the ceiling at a 45 degree angle where operators load the finished cases onto pallets ready for retail distribution.

The XH conveyor was the ideal product
“The FlexLink XH conveyor was the ideal product for this application. Using the roller cleated chain simplified the design of the inclined elevators and provided a cost-effective reliable solution”, says Chris Smith, Managing Director at ADM Automation. The wide variation in carton sizes meant that sections of guidance mounted in the roof needed automatic adjusting when different cartons were traveling along the conveyor. 

High throughput and no maintenance
In addition to this, because of the high throughput rate, entry of cartons onto the main conveyor had to be carefully synchronized to maximize the number of cartons travelling at any one time. This was achieved within the control system software by altering the timing of carton transfers depending on the product flow through the main conveyor. Extra lines are being added this year to handle the increase in production at the Bristol Myers Cramlington site. “We are pleased with the systems in place and maintenance so far on the conveyors has been nonexistent”, comments Mr Herbert. “The system has improved our efficiency and equipped us to cope with future expansion.”